Embodiments of the disclosure relate to a polymer composition. The polymer composition includes from 0% to 80% by weight of a polyolefin component and from 20% to 100% by weight of a thermoplastic elastomer component. The polymer composition has an elastic modulus of less than 1500 MPa at −40° C. as measured using dynamic mechanical analysis according to ASTM D4065. Further, the polymer composition has a coefficient of thermal expansion as averaged over the temperature range of −40° C. to 25° C. of more than 120×10−6/K when measured according to ASTM E831, and the polymer composition has a thermal contraction stress of no more than 4.0 MPa at −40° C. as measured using dynamic mechanical analysis. Additionally, embodiments of an optical fiber cable having a cable jacket made of the polymeric composition are disclosed herein.
|
1. A polymer composition comprising:
from 0% to 80% by weight of a polyolefin component; and
from 20% to 100% by weight of a thermoplastic elastomer component;
wherein the polymer composition has an elastic modulus of at most 1500 MPa at −40° C. as measured using dynamic mechanical analysis according to ASTM D4065;
wherein the polymer composition has a coefficient of thermal expansion as averaged over the temperature range of −40° C. to 25° C. of at least 120×10−6/K when measured according to ASTM E831; and
wherein the polymer composition has a thermal contraction stress of at most 4.0 MPa at −40° C. as measured using dynamic mechanical analysis.
11. An optical fiber cable comprising:
at least one optical fiber;
a polymeric jacket that surrounds the at least one optical fiber;
wherein the polymeric jacket is formed at least in part from a polymer composition comprising:
from 0% to 80% by weight of a polyolefin component;
from 20% to 100% by weight of a thermoplastic elastomer component;
wherein the polymer composition has an elastic modulus of at most 1500 MPa at −40° C. as measured using dynamic mechanical analysis according to ASTM D4065;
wherein the polymer composition has a coefficient of thermal expansion as averaged over the temperature range of −40° C. to 25° C. of at least 120×10−6/K when measured according to ASTM E831; and
wherein the polymer composition has a thermal contraction stress of at most 4.0 MPa at −40° C. as measured using dynamic mechanical analysis.
2. The polymer composition of
3. The polymer composition of
4. The polymer composition of
5. The polymer composition of
8. The polymer composition of
9. The polymer composition of
10. The polymer composition of
12. The optical fiber cable of
13. The optical fiber cable of
14. The optical fiber cable of
15. The optical fiber cable of
16. The optical fiber cable of
17. The optical fiber cable of
18. The optical fiber cable of
19. The optical fiber cable of
20. The optical fiber cable of
21. The optical fiber cable of
22. The optical fiber cable of
23. The optical fiber cable of
24. An optical fiber drop cable comprising:
at least one optical fiber;
a buffer tube disposed around the at least one optical fiber;
a plurality of tensile yarns disposed around the buffer tube;
a polymeric jacket disposed around the plurality of tensile yarns;
wherein the polymeric jacket is formed at least in part from the polymer composition according to
|
This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application Ser. No. 62/810,421 filed on Feb. 26, 2019, the content of which is relied upon and incorporated herein by reference in its entirety.
The present invention is related to a polymer composition having a low modulus of elasticity and, in particular, to a polymer composition particularly suitable for use as an optical fiber cable jacket. Some polyolefins have advantageous properties for use as cable jacketing materials for a variety of cable types. In particular, certain polyolefins have good flexibility and are able to maintain certain relevant mechanical properties over a range of operating temperatures. The polyolefins can be extruded to surround the cable so as to help protect the interior components of the cable from the environment in which the cable is deployed.
In one aspect, embodiments of the present disclosure relate to a polymer composition. The polymer composition includes from 0% to 80% by weight of a polyolefin component and from 20% to 100% by weight of a thermoplastic elastomer component. The polymer composition has an elastic modulus of at most 1500 MPa at −40° C. as measured using dynamic mechanical analysis according to ASTM D4065. Further, the polymer composition has a coefficient of thermal expansion as averaged over the temperature range of −40° C. to 25° C. of at least 120×10−6/K when measured according to ASTM E831, and the polymer composition has a thermal contraction stress of at most 4.0 MPa at −40° C. as measured using dynamic mechanical analysis.
In another aspect, embodiments of the present disclosure relate to an optical fiber cable. The optical fiber cable includes at least one optical fiber and a polymeric jacket that surrounds the at least one optical fiber. The polymeric jacket is formed at least in part from a polymer composition including from 0% to 80% by weight of a polyolefin component and from 20% to 100% by weight of a thermoplastic elastomer component. The polymer composition has an elastic modulus of at most 1500 MPa at −40° C. as measured using dynamic mechanical analysis according to ASTM D4065. Further, the polymer composition has a coefficient of thermal expansion as averaged over the temperature range of −40° C. to 25° C. of at least 120×10−6/K when measured according to ASTM E831, and the polymer composition has a thermal contraction stress of at most 4.0 MPa at −40° C. as measured using dynamic mechanical analysis.
In yet another aspect, embodiments of the present disclosure relate to an optical fiber drop cable. The optical fiber drop cable includes at least one optical fiber and a buffer tube disposed around the at least one optical fiber. Further, the optical fiber drop cable includes a plurality of tensile yarns disposed around the buffer tube and a polymeric jacket disposed around the plurality of tensile yarns. The polymeric jacket is formed at least in part from a polymer composition consisting essentially of from 0% to 80% by weight of a polyolefin component, from 20% to 100% by weight of a thermoplastic elastomer component, and from 0% to 40% by weight of a filler component. The polymer composition has an elastic modulus of 200 MPa to 1500 MPa at −40° C. as measured using dynamic mechanical analysis according to ASTM D4065, and the polymer composition has a coefficient of thermal expansion as averaged over the temperature range of −40° C. to 25° C. of 120×10−6/K to 300×10−6/K when measured according to ASTM E831.
Additional features and advantages will be set forth in the detailed description that follows, and in part will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and claims hereof, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understand the nature and character of the claims.
The accompanying drawings are included to provide a further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the description serve to explain principles and the operation of the various embodiments.
The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.
Referring generally to the figures, various embodiments of a polymer composition having a low modulus of elasticity, especially down to the temperature −40° C., are provided. The low modulus of elasticity of the polymer composition leads to a reduction in contraction force at −40° C. In embodiments, the polymer composition is utilized as a component of an optical fiber cable, in particular as a cable jacket. As a cable jacket material, the polymer composition improves the temperature cycling performance of optical fiber cables. Advantageously, by using a cable jacket made of the disclosed polymer composition, stiff or hard glass yarns can be replaced with, e.g., soft aramid yarns as tensile elements, which allows for bending performance to be improved. Additionally, such cables can be made more cost-effectively because smaller strengthening elements (e.g., glass-reinforced plastic strengthening rods) can be used and because more fibers can be included in the optical fiber cable without sacrificing the low temperature performance. Alternatively, a cable jacket of the disclosed polymer composition allows for the use of smaller tubes and, therefore, a smaller cable outer diameter as a result of the lower contraction of the overall cable at cold temperatures. In embodiments, the polymer composition can be used to reduce the thermal strain on optic fiber cable components (e.g., outer cable jackets, inner cable jackets, binder layers, etc.) for cables such as drop cables, loose tube cables, ribbon cables, indoor cables, etc. While embodiments of the polymer composition are discussed in the context of optic fiber cables, such discussion is not intended to limit the possible contexts and applications in which the polymer composition can be utilized.
As mentioned above, the disclosed polymer composition has particular applicability for reducing the thermal contraction strain in loose tube optic fiber cables. One way to express the thermal strain of a loose tube cable is provided in the following equation:
where E is a material's elastic modulus, A is a material's cross-sectional area, and a is a material's coefficient of thermal expansion (CTE). In the presently disclosed polymer composition, the components of the polymer composition are selected so as to reduce thermal contraction of the cable jacket or inner jacket material, which happens at cold temperatures and causes optical attenuation increase. By reducing the thermal strain, the thermal contraction stress is reduced. In previous attempts to reduce thermal strain, focus was made on reducing the CTE of the cable jacket material. However, while such compositions were successful in reducing thermal strain, the cost of the low-CTE material was prohibitively high for certain applications, and the low-CTE jacket material had higher surface friction than other conventional materials, which was disadvantageous for certain cable installation methods (such as “jetting” or “blowing” the cable through ducts). Additionally, the low-CTE materials tended not to be compatible with certain cable access technologies because the low-CTE material was too compatible with the access feature (e.g., strip of polypropylene running along the longitudinal axis of the cable jacket), leading to enhanced adhesion between the low-CTE material and the access feature.
Thus, in contrast to low-CTE compositions, embodiments of the presently disclosed polymer composition seek to reduce the elastic modulus over the cable operating temperature range of −40° C. to 80° C. In this regard, the presently disclosed polymer composition includes a mixture of a polyolefin component and a thermoplastic elastomer component. Embodiments of the disclosed polymer composition have an elastic modulus that is below 1500 MPa over the entire temperature range from −40° C. to 80° C. Further, in embodiments, the polymer composition exhibits a thermal contraction stress of no more than 4.0 MPa at −40° C. In embodiments, the polymer composition is used as a cable jacket that surrounds one or more buffer tubes that hold optical fibers or optical fiber ribbons, and in other embodiments, the polymer composition is used as an inner layer jacket of a bilayer jacket structure with an outer layer of a standard cable jacket material.
In embodiments, the polymeric composition includes a polyolefin component, a thermoplastic elastomer component, and optionally a filler component. In exemplary embodiments, the polyolefin component can include at least one of medium-density polyethylene (MDPE), high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), or polypropylene (PP) copolymer, among other polyolefins. In embodiments, the polyolefin component is from 0% to 80% by weight of the polymer composition. In other embodiments, the polyolefin component is from 20% to 70% by weight of the polymer composition, and in still other embodiments, the polyolefin component is from 40% to 60% by weight of the polymer composition.
In exemplary embodiments, the thermoplastic elastomer component of the polymer composition can include at least one of olefin block copolymers, olefin random copolymers, ethylene-propylene rubber (EPR), ethylene-propylene-diene rubber (EPDM), ethylene-octene (EO), ethylene-hexene (EH), ethylene-butene (EB), ethylene-vinyl acetate (EVA), ethylene-butyl acetate (EBA), and styrene-ethylene-butadiene-styrene (SEBS), among others. In an embodiment, the polymer composition includes from 20% to 100% by weight of the thermoplastic elastomer. In further embodiments, the polymer composition includes from 30% to 80% by weight of the thermoplastic elastomer, and in other embodiments, the polymer composition includes from 40% to 60% by weight of the thermoplastic elastomer.
In embodiments in which it is included, the filler component can be added to reduce cost or to provide an additional functionality. For example, the filler component can be configured to provide flame retardance. Exemplary flame retardant fillers include, alumina trihydrate (ATH), magnesium hydroxide (MDH), boehmite (aluminum oxide hydroxide), calcium carbonate (CaCO3), and intumescent additives (e.g., melamine, ammonium polyphosphate, pentaerythritol, polyphosphinates and other phosphorus-containing compounds), among others. The filler component may include one or more of the flame retardant additives and/or one or more other filler materials, such as talc, carbon black, TiO2, etc. In a particular embodiment, the filler material comprises at least 2.5% by weight of carbon black for UV protection in outdoor applications. In embodiments, the polymer composition includes up to 40% by weight of the filler component.
In embodiments, the polymeric composition consists essentially of just the polyolefin component, the thermoplastic elastomer component, and optionally the filler component. That is, the polymeric composition may contain no additional components. However, in certain embodiments, the polymer composition may include other minor processing and/or performance additives that do not materially affect the basic and novel characteristics of the disclosed polymeric composition. For example, a dispersant may be added to aid dispersion of the filler component. Still further, the polymer composition can include up to 1% by weight of a low friction additive, such as a fatty acid or a fatty acid amide. For example, the fatty acid can have a carbon backbone of between C6 to C25 and be saturated or unsaturated. Specific examples include caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, etc. Similarly, the fatty acid amide can have carbon backbones, for example, of between C6 and C25 and be saturated or unsaturated.
In embodiments, the polymer composition is prepared via extrusion. In a specific embodiment, the polymer composition is prepared via twin screw extrusion. In the particular context of an optic fiber cable, the polymer composition can be extruded as a jacket for an optical fiber cable and/or another component of the optical fiber cable.
In an embodiment, the elastic modulus (alternatively, storage modulus) at −40° C. as measured by dynamic mechanical analysis (DMA) in accordance with ASTM D4065 is at most 1500 MPa. In a further embodiment, the elastic modulus at −40° C. as measured by DMA is at most 1000 MPa, and in still another embodiment, the elastic modulus at −40° C. as measured by DMA is at most 500 MPa. In embodiments, the elastic modulus at −40° C. as measured by DMA is in the range of 200 MPa to 1500 MPa. Further, in embodiments, the CTE, as measured from −40° C. to 25° C., is at least 120×10−6/K. In other embodiments, the CTE is at least 140×10−6/K, and in still other embodiments, the CTE is at least 160×10−6/K. In embodiments, the CTE is at most 300×10−6/K. Still further, in embodiments, the thermal contraction stress at −40° C. as measured using a dynamic mechanical analyzer is at most 4.0 MPa. In other embodiments, the thermal contraction stress at −40° C. is at most 3.0 MPa, and in still other embodiments, the thermal contraction stress at −40° C. is at most 2.0 MPa.
Several exemplary polymer compositions were prepared according to the compositions provided in Table 1, below. C1 and C2 are comparative examples, and E1-E5 are examples according to the present disclosure. In Table 1, LLDPE corresponds to Borstar® LE8707 (available from Borealis AG, Vienna, Austria), OBC1 corresponds to the olefin block copolymer INFUSE™ 9100, LDPE corresponds to AGILITY™ 1021, OBC2 corresponds to INFUSE™ 9500, and OBC3 corresponds to INFUSE™ 9807 (the INFUSE™ and AGILITY™ polymers are available from The Dow Chemical Company, Midland, Mich., USA). OBC1 and OBC2 have the same density of 0.877 g/cm3, but OBC2 had a higher melt index (5 g/10 min vs 1 g/10 min (2.16 kg @ 190° C.)). OBC3 had a lower density than OBC1 and OBC2 at 0.866 g/cm3, but OBC3 had the highest melt index (15 g/10 min).
TABLE 1
Formulations and Properties Polymer Compositions
Weight
Thermal Contraction
Composition
Ratio
Stress (MPa)
C1
LLDPE
100/0
4.85
C2
LLDPE/SEBS/Clay
50/40/10
1.78
E1
LLDPE/OBC1
70/30
2.95
E2
LLDPE/OBC1
50/50
1.44
E3
LLDPE/OBC1/CaCO3
40/40/20
1.56
Masterbatch
E4
LDPE/OBC2
30/70
0.97
E5
LDPE/OBC3
50/50
1.79
As shown in Table 1, the thermal contraction stress for each composition C1 and C2 and E1-E5 was measured. In particular, the thermal contraction stress was measured using a dynamic mechanical analyzer (DMA) on an extruded sample held between two clamps by reducing the temperature from 35° C. to −40° C. and measuring the contraction stress at −40° C. As can be seen in Table 1, C1, which contained only LLDPE, exhibited a contraction stress of 4.85 MPa, which is significantly higher than C2 and E1-E5. C2 was a low-CTE formulation that had a contraction stress below 2 MPa, but as discussed below, the elastic modulus for C2 was much higher than 1500 MPa at −40° C. The CTE of C2 was also lower over the temperature range of −40° C. to 40° C. than for E1-E5. In a comparison of E1 and E2, it can be seen that the contraction stress decreases as the amount of thermoplastic elastomer (OBC1) increases; however, both E1 and E2 are below a contraction stress of 4.0 MPa. Further, as shown in E3, the polyolefin and thermoplastic elastomer remain in a 1:1 ratio, but 20% by weight of a filler is added to the masterbatch. As can be seen, the contraction stress only slightly increases from E2. E4 and E5 demonstrate the contraction stress for compositions containing another polyolefin, LDPE. As with E1 and E2, the contraction stress decreases as the amount of thermoplastic elastomer increases.
The elastic moduli of the C1, C2, E2, and E3 were obtained using DMA and are shown in
The polymer composition disclosed herein can be applied in a variety of contexts. In a particular embodiment shown in
In one embodiment, the polymer composition is incorporated into the cable jacket 22 of fiber optic cable 20. In another embodiment, the polymer composition is used to upcoat the central strength member 34 to form the outer coating layer 36. For example, the selection of the number of buffer tubes 30 can define an interior open geometry that is filled/supported by the central strength member 34 and outer coating layer 36. In order to reduce the cost of the optic fiber cable 20, the central strength member 34 can be made as thin as possible while still providing the necessary support for the cable 20. The remainder of the interior open geometry can be filled with the outer coating layer 36 by upcoating the polymer composition on the central strength member 34. In this way, the cost of providing the central strength member 34 and outer coating layer 36 is reduced as the presently disclosed polymer composition used to form the outer coating layer 36 is generally less expensive in terms of material cost than the central strength member 34.
Also, using the polymer composition disclosed herein provides several advantages. In particular, the polymer composition can be used to produce optic fiber cables with enhanced thermal performance and reduced manufacturing cost. Ultimately, incorporating the disclosed polymer composition in various components of the optic fiber cables can help to realize the goals of reducing buffer tube size, shortening lay lengths, and driving cable design to concurrent performance limits under load and at low temperature.
Further, polymer compositions made according to the embodiments disclosed herein offer several additional advantages when used as components for optic fiber cable. For example, the polymer composition can help expand the optical fiber cable operating temperature range to −40° C. or below. Also, the lower thermal contraction stress of less than 4.0 MPa can reduce the attenuation of optic fibers in contact with the polymer composition that results from the contraction of the polymer composition in cold environments. Additionally, the polymer composition can allow for smaller buffer tubes to be used, resulting in lower material cost and lower overall product cost. As discussed above, the polymer composition can help to reduce the diameter (and consequently the cost) of the central strength member. Further, because of the potential to produce smaller cable sizes by using the disclosed polymer composition, the resultant cable is expected to have better blowing performance during installation.
Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article “a” is intended to include one or more than one component or element, and is not intended to be construed as meaning only one.
It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the disclosed embodiments. Since modifications, combinations, sub-combinations and variations of the disclosed embodiments incorporating the spirit and substance of the embodiments may occur to persons skilled in the art, the disclosed embodiments should be construed to include everything within the scope of the appended claims and their equivalents.
Bringuier, Anne Germaine, Li, Yanfei, Cheng, Xiaole
Patent | Priority | Assignee | Title |
Patent | Priority | Assignee | Title |
10131774, | Nov 16 2016 | Corning Optical Communications LLC | Fiber optic cable having low thermal strain and methods of manufacturing the same according to ASTM D4065 and D638 |
10591691, | Feb 13 2018 | SUPERIOR ESSEX INTERNATIONAL INC | All-dielectric self-supporting fiber optic cable |
6215931, | Jan 26 1999 | DRAKA COMTEQ B V | Flexible thermoplastic polyolefin elastomers for buffering transmission elements in a telecommunications cable |
9915799, | Oct 14 2014 | PRYSMIAN S P A | Central loose tube optical-fiber cable |
20070183729, | |||
20080279514, | |||
20160032096, | |||
20170235069, | |||
20180134883, | |||
20190154934, | |||
JP8262294, | |||
WO2016060647, |
Executed on | Assignor | Assignee | Conveyance | Frame | Reel | Doc |
Jan 15 2020 | CHENG, XIAOLE | Corning Research & Development Corporation | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 051794 | /0973 | |
Jan 16 2020 | BRINGUIER, ANNE GERMAINE | Corning Research & Development Corporation | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 051794 | /0973 | |
Jan 16 2020 | LI, YANFEI | Corning Research & Development Corporation | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 051794 | /0973 | |
Feb 12 2020 | Corning Research & Development Corporation | (assignment on the face of the patent) | / |
Date | Maintenance Fee Events |
Feb 12 2020 | BIG: Entity status set to Undiscounted (note the period is included in the code). |
Date | Maintenance Schedule |
Nov 23 2024 | 4 years fee payment window open |
May 23 2025 | 6 months grace period start (w surcharge) |
Nov 23 2025 | patent expiry (for year 4) |
Nov 23 2027 | 2 years to revive unintentionally abandoned end. (for year 4) |
Nov 23 2028 | 8 years fee payment window open |
May 23 2029 | 6 months grace period start (w surcharge) |
Nov 23 2029 | patent expiry (for year 8) |
Nov 23 2031 | 2 years to revive unintentionally abandoned end. (for year 8) |
Nov 23 2032 | 12 years fee payment window open |
May 23 2033 | 6 months grace period start (w surcharge) |
Nov 23 2033 | patent expiry (for year 12) |
Nov 23 2035 | 2 years to revive unintentionally abandoned end. (for year 12) |